Composition construction



, Line 5, 1928. w. K. NELSON COMPOSITION CONSTRUCTION Filed Oct. 192vInfnfir f ovngy s Patented June 5, 1928.

PATENT OFFICE.

WILLIAM K. NELSON, OF CHICAGO, ILLINOIS.

COMPOSITION CONSTRUCTION.

Application filed October 1,

My invention relates to a composition construction for floors, roofs,walls or other structures wherein a coating of a cement-itious materialsuch as Portland cement, con- .crete, terrazzo or other composition isapplied over a body of porous filling or insulating material such ascinder-concrete or east cellular gypsum; and, it also relates to a noveland improved method of installing such constructions. My inventionrelates particularly to a construction wherein the cementitious coatingis applied over a body of cast cellular gypsum insulating material ofthe type described in my Patent No.

1,641,641 issued September 6, 1927.

In constructions such as are commonl employed in modern buildings in theoors, roofs, Walls, etc., a concrete deck or other supporting orprotecting means is provided which is usually from three to eight inchesin thickness. A body of porous filling or insulating material from twoto eight inches in thickness is applied over or placed against theconcrete deck or other supporting or protecting means. A topping orcoating of cementitious material from one-half to two inches inthickness is applied over the filling or insulating material and thenthe cementitious material is t-rowelled down to provide a hard densewearing or finished surface. A blanket of wet sawdust is usually appliedover the cement and is permitted to remain for a period of seven to tendays to insure proper setting of the cement.

Great difficulty is experienced with such a construction in obtaining alasting wearing surface, free of cracks, curlings, or otherimperfections, on the cementitious coating or topping. If the filling orinsulating material is fairly wet when the coating or topping ofcementitious material is applied thereover, the under surface of thecementitious layer will remain in a fairly wet condition for an extendedperiodof time while the exposed upper or outer surface thereof issubjected to" fast drying after the blanket of sawdust has been removed.Under such conditions the drier upper or outer surface of thecementitious layer undergoes considerable contraction whiletherelatively moist under surface thereof does not similarly contract, andwill even expand under certain eondit ions. Such unequal contractingforces, or contracting and expansive forces, present 1927. Serial No.223,294.

in the respective upper and lower portions of the cementitious layer,frequently cause a serious break-down in the structure. If the fillingor insulating material is fairly well dried before the coating ortopping of cementitious material is applied thereover, difliculty inretaining a suflicient amount of moisture in the cementitious .layer forits proper setting and satisfactory bonding to the filling andinsulating material, is encountered. The dry porous filling orinsulating material quickly absorbs the water from the wet cementitiousmaterial which leaves the latter in .a pasty, crumbly or weakenedcondition. If more water be added repeatedly to the cementitiousmaterial in an eflort to obtain better trowelling and settingconditions, the process of absorption continues until the filling orinsulating material thereunder reaches the saturation point in whichcase the conditions become similar to those of an originally wet fillingor insulating material hereinbefore mentioned. 4

,One of the objects of myinvention is to provide a construction in whichthe coating or topping of cementitious material will set normally andproperly, be bonded intimately to the filling or insulating materialunderneath and have a smooth, level wearin or finished surface in whichno imperfectlons in the course of time will develop due to any residualmoisture that may be present in the filling or insulating material. Afurther object of myinvention is to provide a novel method of installinga composition construction of the type mentioned wherein the passage ofmoisture from the porous filling or insulating material to the coatingor topping of cementitious material or vice verse is controlled by theemployment between the two materials of a film of such a nature and ofsuch a thickness that proper trowelling conditions onthe surface of thecementitious material will be provided, that only a small but asufficient-amount of moisture, carrying some of the cementitiousmaterial in solutionor suspension, will penetrate the filling orinsulating material suffieientl-y to insure the formation of a permanentbond between the two materials'and that substantially uniform moistureconditions will be maintained throughout the cementitious material aftersetting thereof thereby effectively preventing the development of forcesinjurious to'or destructive of the structure.

The objects of my invention can be readily accomplished by spraying, orotherwise applying, a thin film of a suitable wa terrepelling agent, orhardening and waterrepelling agent, on the dried or set up surface ofthe body of filling or insulating material before the coating or toppingof cementitious material is applied thereover. The agent employed maycomprise asphalt pitch, a suitable wax, such as parafiine wax, and afluid, preferably a solvent of the aromatic ser'es, such as xylol.

The prefer ed means by which I have produced my improved constructionsare disclosed'in thev drawing and are hereinafter specificallydescribed. That which I believe to be new and desire to cover by LettersPatent is set forth in the claims.

The figure of the drawing is a perspective view of fragmentary portionsof a.

floor and a wall, each constructed in accordance with the principles ofmy inven tion.

The floor illustrated in the accompanying drawing comprises a deck 3, abody of filling or insulating material .4 installed over said deck,.afilm 5 of a suitable agent applied over the top surface of the body 4,and a coating or topping '6 of cementitious material.

- The wall shown in the drawing comprises a protective tier or layer ofhollow tile 7 laid-in mortar, a tier or layer of castporoiis mineralinsulating blocks 8 laid in mortar or pitch against or adjacent theinner surface of the tile, a film 9 of a suitable agent applied over theinner surface of'the blocks 8, and a coating or layer 10 9f a-suitablecementitious material.

The deck 3 may be made of any suitable supporting material. It willusually be from three to eight inches in thickness and be made of suchmaterial as concrete, brick,

gypsum blocks or slabs, or planking. The

protective tier or layer 7 of the wall may also be made of any suitablematerial andof any desired thickness, hollow tile being merely shown asan example of what may be used. F

The filling or insulatingbodies 4 and 8 may be of any suitable materialor composition, for example, cinder-concrete or cast cellular mineralmaterial. I prefer, however, to be employ cast cellular gypsum materialof the type described in my aforesaid Patent No. 1,641,641. Each of thebodies 4 and- 8 will ordinarily be from two to eight inches inthickness. The body 4 .must withstand considerable weight and thecomposition therefor is preferably such that the dry cast material willweigh approximately twenty-four 'lbs. per cubic foot.

a suitable.

The body 8 ordinarily will not be subjected to any severe strain and thecomposition therefor may be such that the dry cast material will weighfifteen ,to eighteen lbs.

per cubic foot. The bodies 4 and 8 may water-repelling material, or anysuitable hardening and water-repelling material, adapted to form asuitable hydrostatic barrier between the respective coatings or toppings6 and 10 and the bodies of filling or insulating material thereunder.The films 5 and 9 may be made from various ingredients such, forexample, as any one or various combinations of those mentioned in -thefollowing group: pitch, parafline wax,

carnauba wax, or other similar waxes, gum copal, gum dammar, or othersimilar gums, aluminum "stearate or other metallic soaps, cut ordissolved in a suitable fluid such, for

example, as any one or various combinations of the fluids mentioned inthe following group: benzine kerosene or any other solvent or cuttingmaterial from the aliphatic series, or xylol, solvent naphtha or anyother solvent or cutting material from A suitable agent for the aromaticseries. producingthe films may also be made from any one or anycombination of the ingredients mentioned in the first group and/or anyone or any combination of the ingredients mentioned in the second groupin combination with an emulsifying substance such as a soap or gumforming an emulsion with water. A satisfactory and inexpensive'film canbe made from a solution compounded in the following proportions andcomprising 2 lbs. asphalt pitch, 2 lbs. parafiine. wax and 1 gallonxylol.

faces of the respective filling or insulating materials in any suitablemanner as, for example, by spraying, by mopping or by brushing thesolution thereonto.'

The coatings or toppings 6 and 10 ordinarily will each be from.one-half-inch to two inches in thickness and they may be made of anysuitable cementitious material such as Portland cement, concrete,terrazzo The films may be applied to the dry or setup surrial thereunderserves as an effective hydrostatic barrier between the two materials andeffectively controls the passage of moisture from'the coating or toppingto the filling or insulating material iereunder and from the filling orinsulating material to the coatin or topping thereover.

he thickness of the film of the waterrepelling agent employed willdepend upon such conditions as the moisture content and the degree ofporosity of the body of filling or insulating material. The film shouldbe thick enough to bar the passage of an excessive or'objectionableamount of moisture from one material to the other while at the same timeis shpuld not be so thick as to prevent the passage of a small butsuflicient amount of moisture carrying some of the cementitious materialin solution or suspension to enetrate therethrough and into the "porousHing or insulating material thereunder to such an extent as to insurethe formation of an intimate and permanent bond between'the twomaterials and to provide proper trowelling conditions on the surface ofthe cementitious material. It has been j found thata relativelydryfilling or insulating-material will require a slightly heavier film-thanthat re uired for a comparatively moist or wet filling or insulatingmaterial due to the greater suction or absorption ca- 7 pacity of thefirst mentioned material.

Should the. body of filling or insulating material be fairly wet, thefilm of water-re; pelling agent. applied thereover will prevent anyexecessive or objectionable amount of moisture from leaving the bodyoffilling or insulating material and entering the'coa'ting or topping ofcementitious material and the moisture conditions of the latter,therefore, will be maintained substantially uniform throughout, therebyeffectively preventing the developmenttherein of opposing conditionswhich. would tend to injure or'destroy the cementitious layer by causingthe surface thereof to crack, curl up or have other imperfections.However, the porous (wet fillingor insulating material, has sufficientsuctlon 'or absorption capacity to draw through the film some ofthe-moisture from the cementitious material thereby insuring, ashereinbefore described, the desired bond between the two materials andalso providing proper trowelling conditions on the surface of thecementitious material by withdrawing sufiicient water therefrom topermit trowelling without undue delay.

When the body of filling or insulating material is fairly well dried,the film of and, in such case, the film of water-repellin agentmaintains substantially uniform and satisfactory moisture conditionsthroughout the cementitious layer with the resultant advantage ofreventing the serious de- 70 fects in its sur ac'e hereinbefore noted.However, suflicient moisture from the cementitious la er penetrates thefilm and into the porous fi ling or insulating material underneat-h toprovide, as I have heretofore ex- 76 plained, the desired bond betweenthe two materials. The film also insures suflicient moisture beingretained in the cementitious material to maintain the material at thedesired plasticity and stiffness for proper trowellmg of the surface.

A film of water-repellin agent as hereinbefore described also ten s toharden the surface of the filling or insulating material over which-itis applied. If the filling or I insulating material be of the castcellular gypsum type such as is described in my aforesaid atent, pouredon the job, I prefer to applyt e film as soon as the material has set upsufficient] to permit operations without danger of reaking down thecellular formation. On such aninsulating or filling material the filmcan be applied ordinarily within twenty to thirty minutes after thematerial has been poured in place and, when that is done, the film.maintains the coated surface of the insulating material in ahardenedstate' due in some cases to the hardening properties of the filmmaterial and in all cases by preventing the excess or free P moisture inthe filling or insulating material from assing in any substantial amountthrougi the treated surface which would cause said surface to beweakened.

' By the use of a film of a water-repelling agent such as thathereinbefore described, filling or insulating materials. in a dry statemay be employed. This is advantageous in many installations,particularly when pipes, conduits, cables. electric wires and the likeU" are to be imbedded in the filling or insulating material and it isdesired to keep moisture away from them. Such a film also permits theuse of a filling on insulating 'material of somewhat lighter weightbecause such a material is strongest when dry and. since the filmprevents any ,execessive or objectionable amount of moisture fromentering the filling or insulating material, the strength of the latteris notimpaired. j

ile I prefer to employ constructions li e thosedisclosed in my drawingand as above described, I wish toha've it understood that I do notdesire to limit my invention tothe particular constructions shown anddescribed, nor to the particular materials described, nor to the methodspecificall de scribed, except only in so far as the ,c aims are sorestricted by the state of the art, since it is evident that changes maybe made iii) a monolithic structure.

2. A composition construction for floors, roofs, walls-and the likecomprising a body of cast cellular gypsum material having on one of itssurfaces a thin film-like coating of a water-repelling agent, and alayer of cementitious material on the coated surface of said gypsummaterial, said materials being in intimate bond with each other andforming a monolithic structure. 7

3. A composition construction for floors, roofs, walls and the likecomprising a body of cast porous mineral material having on one of itssurfaces a thin film-like coating of a hardening and mater-repellingagent, and a layer of cementitious material on the coated surface ofsaid porous material,

said materials being in intimate bond with each other and forming amonolithic struc-* ture.

a. A composition construction for floors. roofs, walls and the likecomprising a body of cast cellular gypsum material having on one of itssurfaces a thin film-like coating of a hardening and water-repellingagent, and a layer of cementitious material on the coated surface ofsaid gypsum material, said materials being in intimate bond with eachother and forming a monolithic structure.

5. A composition construction for floors, roofs, walls and the likecomprising a body of cast porous mineral material having on one of itssurfaces a thin film-like coating of an agent comprising pitch, wax anda fluid,

. and a layer of cementitious material on the coated surface of saidporous material, said materials being in intimate bond with each otherand forming a monolithic structure.

6. A composition construction for floors, roofs, walls and the likecomprising a body of cast porous mineral material having on one of itssurfaces a thin film-like coating of an agent comprising pitch, wax anda solvent of the aromatic series, and a layer of cementitious materialon the coated surface of said porous material, said materials being inintimate bond with each other and forming a monolithic structure.

7. A composition construction for floors,

. roofs, walls and the like comprising a body of cast cellular gypsummaterial having on one of its surfaces a thin film-like coating of asolution comprising asphalt pitch, paraffine wax and xylol, and alayerof cementitious material on the coated surface of said gypsum material,said materials being in intimate bond with each other and forming amonolithic structure.

8; A composition construction for floors, roofs, walls and the likecomprising a body of cast cellular gypsum material having on one ofits-surfaces a thin film-like coating of a solution compounded insubstantially the following proportions and comprising 2 lbs. asphaltpitch, 2 lbs. paraiiine wax and 1 gallon xylol, and 'a layer ofcementitious material on the coated surface of said gypsum, material,said materials being in 1ntimate bond with each other and forming amonolithic structure.

9. In the method of installing a monolithic composition construction forfloors, roofs, walls and the like comprising a body of cast porousmineral material coated with a layer of cementitious material, the stepof controlling the passage of moisture from one material to the other byinterposing between the two materials a film of a water-repelling agentand of such thickness that proper trowelling conditions will be providedin the cementitious material, that only a small but sufiicient amount ofmoisture carrying some 1 of the cementitious material in solution orsuspension will penetrate the porous material sufliciently to insure theformation. of a permanent bond between the two materials and thatsubstantially uniform moisture conditions will be maintained throughoutthe cementitious material after setting thereof. '10. In the method ofinstalling a monolithic composition construction for floors, roofs,walls andthe like comprising a body of cast cellular gypsum materialcoated with a layer of cementitious material, the step of controllingthe passage of moisture from one material to the other by spraying thesurface of the gypsum material next to the cementitious material with afilmof a hardening and water-repelling agent and of such thickness thatproper trowelling conditions will be provided in the cementitiousmaterial, that only a small but sufficient amount of moisture carryingsome of the cemtentitious material in solution or suspension willpenetrate the g psum material sufficiently to insure the ormation of apermanent bond between the two materials and that substantially uniformmoisture con ditions will be maintained throughout the cementitiousmaterial after setting thereof.

11. A composition construction for floors, roofs, walls and the likecomprising a body of cast porous mineral material having on one of itssurfaces a thin film-like coating of a water repelling agent, and alayer of cementitious material on the coated surface of said porousmaterial and bonded thereto by penetration of said coating by a portionllU liii) I mums v 5 of said cementitiousmaterial into a portioncementitious material on the coated surface of said porous material. ofsaid gypsum material and bonded thereto 12. A composition constructionfor floors, by penetration of said coating by a-portion 10 roofs, Wallsand the like comprising a body of said cementitious material into a.portion 5 of cast cellular gypsum material having on of said gypsummaterial.

one of its surfaces 9. thin film-like coatin of a water repelling agent,and a layer 0 a T WILLIAM K. NELSON.

